Drill Counting Sensor for PCB CNC Machine

Hello guys!

Recently I got access to a CNC machine and I always wanted to work on the Drill Counter and monitor the machine online. Hence, I have prototyped a sensor and shared a step by step procedure of building an IOT based Drill Counter which is used for CNC machines. Thanks to LionCircuits for providing me low-cost proto-boards in just 5 days.

Let's get started...

Step 1: Things Required

1. NodeMCU

2. ADXL345 accelerometer

3. Jumper wire - female to female

4. Micro USB cable A to B

5. Arduino IDE on your computer.

Step 2: Installing NodeMCU Board Package

1. Open up Arduino IDE. Go to Files -> Preferences. Enter this Code into Additional Board Manager URLs field.

2. Now go to Tools ->Boards ->Board Manager, and search for ESP8266 and install the package.

Step 3: Connections

Interfacing of ADXL345 accelerometer with NodeMCU has to be done as shown in the image.

Step 4: Mounting on the CNC Machine

In-order to mount on a CNC machine I have embedded the circuit inside a small box as shown in the image.

Step 5: Programming

1. Download and Install Adafruit sensor library and ADXL345 Library.

2. Click "File -> Examples -> Adafruit_ADXL345 -> sensortest" to load the example sketch from the library as shown below.

<p>#include <Wire.h><wire.h><br>#include <Adafruit_Sensor.h><adafruit_sensor.h>
#include <Adafruit_ADXL345_U.h> <adafruit_adxl345_u.h>
 
/* Assign a unique ID to this sensor at the same time */
Adafruit_ADXL345_Unified accel = Adafruit_ADXL345_Unified(12345);
 
void displaySensorDetails(void)
{
  sensor_t sensor;
  accel.getSensor(&sensor);
  Serial.println("------------------------------------");
  Serial.print  ("Sensor:       "); Serial.println(sensor.name);
  Serial.print  ("Driver Ver:   "); Serial.println(sensor.version);
  Serial.print  ("Unique ID:    "); Serial.println(sensor.sensor_id);
  Serial.print  ("Max Value:    "); Serial.print(sensor.max_value); Serial.println(" m/s^2");
  Serial.print  ("Min Value:    "); Serial.print(sensor.min_value); Serial.println(" m/s^2");
  Serial.print  ("Resolution:   "); Serial.print(sensor.resolution); Serial.println(" m/s^2");  
  Serial.println("------------------------------------");
  Serial.println("");
  delay(5000);
}
 
void displayDataRate(void)
{
  Serial.print  ("Data Rate:    "); 
 
  switch(accel.getDataRate())
  {
    case ADXL345_DATARATE_3200_HZ:
      Serial.print  ("3200 "); 
      break;
    case ADXL345_DATARATE_1600_HZ:
      Serial.print  ("1600 "); 
      break;
    case ADXL345_DATARATE_800_HZ:
      Serial.print  ("800 "); 
      break;
    case ADXL345_DATARATE_400_HZ:
      Serial.print  ("400 "); 
      break;
    case ADXL345_DATARATE_200_HZ:
      Serial.print  ("200 "); 
      break;
    case ADXL345_DATARATE_100_HZ:
      Serial.print  ("100 "); 
      break;
    case ADXL345_DATARATE_50_HZ:
      Serial.print  ("50 "); 
      break;
    case ADXL345_DATARATE_25_HZ:
      Serial.print  ("25 "); 
      break;
    case ADXL345_DATARATE_12_5_HZ:
      Serial.print  ("12.5 "); 
      break;
    case ADXL345_DATARATE_6_25HZ:
      Serial.print  ("6.25 "); 
      break;
    case ADXL345_DATARATE_3_13_HZ:
      Serial.print  ("3.13 "); 
      break;
    case ADXL345_DATARATE_1_56_HZ:
      Serial.print  ("1.56 "); 
      break;
    case ADXL345_DATARATE_0_78_HZ:
      Serial.print  ("0.78 "); 
      break;
    case ADXL345_DATARATE_0_39_HZ:
      Serial.print  ("0.39 "); 
      break;
    case ADXL345_DATARATE_0_20_HZ:
      Serial.print  ("0.20 "); 
      break;
    case ADXL345_DATARATE_0_10_HZ:
      Serial.print  ("0.10 "); 
      break;
    default:
      Serial.print  ("???? "); 
      break;
  }  
  Serial.println(" Hz");  
}
 
void displayRange(void)
{
  Serial.print  ("Range:         +/- "); 
 
  switch(accel.getRange())
  {
    case ADXL345_RANGE_16_G:
      Serial.print  ("16 "); 
      break;
    case ADXL345_RANGE_8_G:
      Serial.print  ("8 "); 
      break;
    case ADXL345_RANGE_4_G:
      Serial.print  ("4 "); 
      break;
    case ADXL345_RANGE_2_G:
      Serial.print  ("2 "); 
      break;
    default:
      Serial.print  ("?? "); 
      break;
  }  
  Serial.println(" g");  
}
 
void setup(void) 
{
#ifndef ESP8266
  while (!Serial); // for Leonardo/Micro/Zero
#endif
  Serial.begin(9600);
  Serial.println("Accelerometer Test"); Serial.println("");
 
  /* Initialise the sensor */
  if(!accel.begin())
  {
    /* There was a problem detecting the ADXL345 ... check your connections */
    Serial.println("Ooops, no ADXL345 detected ... Check your wiring!");
    while(1);
  }
 
  /* Set the range to whatever is appropriate for your project */
  accel.setRange(ADXL345_RANGE_16_G);
  // accel.setRange(ADXL345_RANGE_8_G);
  // accel.setRange(ADXL345_RANGE_4_G);
  // accel.setRange(ADXL345_RANGE_2_G);
 
  /* Display some basic information on this sensor */
  displaySensorDetails();
 
  /* Display additional settings (outside the scope of sensor_t) */
  displayDataRate();
  displayRange();
  Serial.println("");
}
 
void loop(void) 
{
  /* Get a new sensor event */ 
  sensors_event_t event; 
  accel.getEvent(&event);
 
  /* Display the results (acceleration is measured in m/s^2) */
  Serial.print("X: "); Serial.print(event.acceleration.x); Serial.print("  ");
  Serial.print("Y: "); Serial.print(event.acceleration.y); Serial.print("  ");
  Serial.print("Z: "); Serial.print(event.acceleration.z); Serial.print("  ");Serial.println("m/s^2 ");
  delay(5000);
}</adafruit_adxl345_u.h></adafruit_sensor.h></wire.h></p>